Fabric and method for making the fabric

ABSTRACT

A fabric and method for making same are described. A destructible material capable of supporting closely spaced stitches is sewn with zigzag stitches of upper threads arranged in rows with overlapping zigzag corners between different rows. Alternate rows of opposite zigzag upper thread stitches are placed on the destructible fabric and interlocked with under threads at the corners to effectively interlock the upper threads. Thereupon, the fabric on which the upper threads were placed is destroyed without affecting the upper and under threads, to leave a loosely knit fabric suitable for garments and the like.

[151 3,653,023 [451 Apr. 25, 1972 United States Patent Rossi 2,332,93110/1943 Riviere...... ......ll2/4i6 3,315,329 4/1967Yoshioka...............................28/76T [54] FABRIC AND METHOD FORMAKING THE FABRIC Primary Examiner-Alfred R. Guest Attorney- Louis H.Reens [72] Inventor: Allred G. Rossi, 322 35th Street, Union` City, NJ.07087 ABSTRACT [22] Filed: July l5, 1969 2,259,025 lO/l 94| CosgroPATENTEDAPRQSIQH 3,658,023

24 26 20/ 2O IO 24 |NVENTOR ALFRED GHNO ROSSI BYRKBWMYL mjmvu) FABRICAND METHOD FGR MAKING THE FABRIC This invention relates to fabrics and amethod of making fabrics. More specifically, this invention relates toloose fabrics `such as lace and a method of utilizing an embroiderymachine for making a fabric.

The embroidery of materials on a high production basis involves highlysophisticated, complicated machines of generally limited capability. Awell known embroidery machine is known as the Schiffli machine.

This invention is directed at the formation of a fabric which can beconveniently and economically manufactured on an embroidery machine.

In the practise of this invention, a material capable of being removedis sewn with rows of closely spaced zigzag upper thread stitches withcertain rows displaced from others to align upper thread rows ofopposite zigzags with other rows to form overlapping comers of thezigzag stitches. Under threads interlock with upper threads at thezigzag corners to provide the interlock between the rows of upperthreads upon removal of the material.

It is, therefore, an object of this invention to provide a method ofmaking a loose fabric. It is still further an object of this inventionto provide a method of making a fabric with an embroidery machine.

These objects and others may be understood from the followingdescription of a preferred embodiment of the invention in conjunctionwith the drawings wherein:

FIG. 1 is a planar enlarged schematic view of a fabric made inacc'ordance with the invention with the foundation fabric indicated forclarity in phantom fashion.

FIG. 2 is a section view of the fabric of FIG. l taken along the line2--2 in FIG. 1.

FIG. 3 is a section view of the fabric of FIG. 1 taken along the line3-3 in FIG. l.

FIG. 4 is a perspective view of the comer interlocking of a pair ofupper threads.

With reference to the FIG. 1, a phantom shown destructible fabricmaterial l0, such as silk, is provided with rows of sewn upper threads.Upper threads 12 through 30 and as many others as desired are sewn tothe fabric l in zigzag rows and are interlocked with under threads suchas 32 through 48 at the corners of the zigzags of the several upperthreads. The upper thread 12, for instance, is sewn to the silk fabricand interlocked with an under thread 32 at the comer 50 and againinterlocked with under thread 32 at corner 52. This zigzag sewing ofthread 12 is continued for the width of the silk fabric 10. A secondupper thread 14 is then sewn to the fabric l0, like upper thread 12, andin fact is placed in parallel adjacency with thread 12. Accordingly, theupper thread 14 interlocks with an under thread 36 at comers such as 54.A third upper thread 16 may be sewn before an upper thread of oppositezigzag is sewn. FIG. 3 illustrates the beginning formation steps inmaking the fabric of this invention. Upper thread 18 is sewn to thefabric l0 with an opposite zigzag from that of threads 12 and 14 and isso spaced to provide an overlap of previously sewn upper threads such as16 and 14. The upper thread 18 interlocks with an under thread 34 atcomers 56, 58 and 60. The corner 56 is so placed that it overlaps thecomer 54 of the previously sewn thread 14 and in this manner interlocksupper thread 18 with upper thread 14 of opposite zigzag.

By continuing the sewing of upper threads with alternate opposite zigzagpatterns, a continuous interlocked fabric is formed on the silk 10.

The silk fabric l0 is then removed by destroying it in a suitablechemical solution or by charring without affecting the upper and underthreads. The remainder then is a fabric of generally loose knit or widespacings between zigzag comers, but possesses the integrity of amaterial for garment purposes and the like.

In the sewing of the upper threads to the foundation material 10, thelatter may be moved while the needles remain stationary. A Schiliembroidery machine may be employed. With such machine, a destructiblematerial such as silk is passed through the machine which is programmedto move the fabric in the direction of arrow 64 with upper threads 12,16 and 24 being sewn in the direction of arrow 66. When the fabric l0 ismoved in the direction of arrow 66, upper threads 18, 22 and 26 are sewnin direction of arrow 64. This process of threading may be repeated asmany times as desired to cover an area as large as necessary. Care mustbe taken to assure that upper threads with opposite zigzags each overlapat least one upper thread with an interlocking at the corners of thezigzags.

The sewn upper threads of FIG. 1 are shown wherein each overlap by anupper thread such as 26 encloses or traps two other upper threads 24 and20. This may clearly be appreciated from the section view of FIG. 2.This view shows the upper thread 26 above the silk fabric 10 overlappingtwo other upper threads 20 and 24 in between corners 68 and 70. Ifdesired, more upper threads may be overlapped or crossed before theoverlapping upper thread is interlocked with an under thread at a zigzagcorner. Thernurnber of crossings depends upon the shape of the zigzag;i.e., its sharpness in angle, the length of its legs, and spacingdensity of parallel threads. These are parameters that may be chosendepending upon the type of effect one desires from the completed fabric.Color of the different threads may be varied.

The ends of the rows of zigzags may be finished in a suitable manner toavoid end fraying.

FIG. 4 perspectively illustrates the comer interlocking effect whichholds the fabric together. Note that the under threads 42 and 44practically are not visible from above. The under threads merely loopthe upper threads 20 and 26, which, if suitably chosen as to size inrelation to that of the under thread, completely obscure the latter. Asthe upper threads draw taut in opposite directions, their zigzag comerslock and fabric integrity is maintained.

The destruction of the silk fabric l0 may be by suitable chemical agentsor by charring. Whatever process is employed to remove the silk, caremust be taken to avoid damage of the upper and under threads.

The fabric thus formed has particular utility in the formation of lace.Lace is generally an ornamental open fabric; however, the fabric made inaccordance with this invention has much greater utility and is ofparticular advantage for embroidery machines which by this inventionbecome suitable for making fabric.

lclaim:

l. A method of forming a fabric comprising the steps of sewing firstrows of upper threads in parallel adjacency with one another in zigzagfashion across a removable material with comers of the zigzagsinterlocked with under threads, sewing second rows of upper threads inparzdlel adjacency with one another in zigzag fashion across theremovable material with comers of the zigzags interlocked with underthreads, said second rows of threads being effectively laterallydisplaced from the first rows of threads to provide overlap of cornersbetween first row and second row threads, and removing the material toleave an interlocked fabric formed of said rows of upper threads andunder threads.

2. The method of making the fabric as claimed in claim 1 wherein thesecond rows of upper threads are sewn with opposite zigzags from that offirst rows of upper threads.

3. The method as claimed in claim 2 wherein adjacent rows of upperthreads are sewn with opposite zigzags.

4. A loosely held fabric comprising:

first rows of upper threads arranged in zigzag fashion in parallelspaced relationship with one another;

second rows of upper threads arranged in zigzag fashion in parallelspaced relationship with one another, said second rows of upper threadslaterally arranged relative to the first rows of upper threads withzigzag comer overlap and under threads interlocking with each of theupper threads at the zigzag comers thereof to form an interlockedfabric.

5. The fabric as claimed in claim 4 wherein the under threads arearranged parallel with upper threads to interlock at corners thereof.

6. The lace fabric as claimed in claim 4 wherein the first and secondrows of upper threads are arranged with adjacent rows 5 crossing oneanother to interlock with further spaced and laterally displaced rows ofupper threads.

1. A method of forming a fabric comprising the steps of sewing first rows of upper threads in parallel adjacency with one another in zigzag fashion across a removable material with corners of the zigzags interlocked with under threads, sewing second rows of upper threads in parallel adjacency with one another in zigzag fashion across the removable material with corners oF the zigzags interlocked with under threads, said second rows of threads being effectively laterally displaced from the first rows of threads to provide overlap of corners between first row and second row threads, and removing the material to leave an interlocked fabric formed of said rows of upper threads and under threads.
 2. The method of making the fabric as claimed in claim 1 wherein the second rows of upper threads are sewn with opposite zigzags from that of first rows of upper threads.
 3. The method as claimed in claim 2 wherein adjacent rows of upper threads are sewn with opposite zigzags.
 4. A loosely held fabric comprising: first rows of upper threads arranged in zigzag fashion in parallel spaced relationship with one another; second rows of upper threads arranged in zigzag fashion in parallel spaced relationship with one another, said second rows of upper threads laterally arranged relative to the first rows of upper threads with zigzag corner overlap and under threads interlocking with each of the upper threads at the zigzag corners thereof to form an interlocked fabric.
 5. The fabric as claimed in claim 4 wherein the under threads are arranged parallel with upper threads to interlock at corners thereof.
 6. The lace fabric as claimed in claim 4 wherein the first and second rows of upper threads are arranged with adjacent rows crossing one another to interlock with further spaced and laterally displaced rows of upper threads. 